Complex harness

ABSTRACT

A complex harness includes first electric wires, each of which includes a first center conductor and a first insulation that covers the first center conductor, a cable including second electric wires, each of which includes a second center conductor and a second insulation that covers the second center conductor, and an inner sheath that covers the second electric wires, and an outer sheath covering the first electric wires and the cable collectively. The first electric wires are extended from an end of the outer sheath. The cable is extended from the end of the outer sheath in a state where the second electric wires are collectively covered by the inner sheath in such a manner that an extension length of the cable from the end of the outer sheath is greater than an extension length of the first electric wires from the end of the outer sheath.

The present application is a Continuation Application of U.S. patentapplication Ser. No. 16/356,177, filed on Mar. 18, 2019, which is aContinuation Application of U.S. patent application Ser. No. 15/869,898,filed on Jan. 12, 2018, now U.S. Pat. No. 10,279,756 B2, issued on May7, 2019, which is a Continuation Application of U.S. patent applicationSer. No. 15/229,667, filed on Aug. 5, 2016, now U.S. Pat. No. 9,902,347B2, issued on Feb. 27, 2018, which is a Continuation Application of U.S.patent application Ser. No. 14/630,346, filed on Feb. 24, 2015, now U.S.Pat. No. 9,463,756 B2, issued on Oct. 11, 2016, which is a ContinuationApplication of U.S. patent application Ser. No. 13/865,881, filed onApr. 18, 2013, now U.S. Pat. No. 9,000,301 B2, issued on Apr. 7, 2015,which is based on and claims priority from Japanese Patent ApplicationNos. 2012-096729 and 2012-215636 filed on Apr. 20, 2012 and Sep. 28,2012, respectively, the entire contents of which are incorporated hereinby reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The invention relates to a complex harness for a vehicle.

2. Description of the Related Art

An ABS sensor used in an ABS (Anti-lock Brake System) of a vehicle isconventionally known. The ABS sensor is to measure a rotation speed of awheel and a sensor portion (sensor head) of the ABS sensor is providedin the vicinity of the wheel. The sensor portion provided in thevicinity of the wheel is connected to a control device (electroniccontrol unit) provided on a vehicle body via an ABS sensor cable.

In recent years, an electric brake in which braking is controlled byelectricity in place of hydraulic pressure is becoming popular. Anelectric parking brake (EPB) which is a motorized parking brake is alsoknown and, in the present specification, the electric brake is meant toinclude also the electric parking brake. In the electric brake, a brakecaliper (actuator) provided on a wheel is connected to a control deviceprovided on a vehicle body via an electric brake cable (see, e.g.,JP-A-2003-92028).

SUMMARY OF THE INVENTION

The conventional ABS sensor cable and the electric brake cable areseparately installed even though both cables are connected tosubstantially the same positions. Thus, the installation thereof isdesired to be improved since the wiring space of the vehicle may belimited and the wiring work thereof may be thereby complicated.

Accordingly, it is an object of the invention to provide a complexharness that allows the efficient use of the wiring space of a vehicleand the facilitation of the wiring work.

(1) According to one embodiment of the invention, a complex harnesscomprises a composite cable comprising an electric brake cable, an ABSsensor cable and an outer sheath,

wherein the electric brake cable and the ABS sensor cable are integratedby being commonly covered with the outer sheath.

In the above embodiment (1) of the invention, the followingmodifications and changes can be made.

(i) The complex harness further comprises a connector at an end portionof at least one of the electric brake cable and the ABS sensor cable,

wherein the electric brake cable and the ABS sensor cable are separatedat an end portion of the composite cable.

(ii) The ABS sensor cable comprises two signal wires and an inner sheathto collectively cover the two signal wires.

(iii) The outer sheath comprises a thermoplastic resin, and wherein theinner sheath comprises a crosslinked thermoplastic resin.

(iv) The outer sheath comprises a thermoplastic urethane, and whereinthe inner sheath comprises a crosslinked thermoplastic urethane.

(v) The crosslinked thermoplastic urethane is formed by crosslinking thethermoplastic urethane with a silane coupling agent added thereto, and

wherein the ABS sensor cable comprises a sensor portion of an ABS sensorintegrated at an end of the ABS sensor cable by a resin mold.

(vi) The complex harness further comprises a separator between the outerand inner sheaths to reduce a fusion-adhesion therebetween.

(vii) The separator comprises a metal and is disposed covering the ABSsensor cable.

(viii) The complex harness further comprises a shield conductor disposedcovering a power wire of the electric brake cable.

(ix) The electric brake cable is used as a conducting path for passingan electric current to operate a mechanism of preventing rotation ofwheels after stopping a vehicle.

Effects of the Invention

According to one embodiment of the invention, a complex harness can beprovided that allows the efficient use of the wiring space of a vehicleand the facilitation of the wiring work.

BRIEF DESCRIPTION OF THE DRAWINGS

Next, the present invention will be explained in more detail inconjunction with appended drawings, wherein:

FIGS. 1A and 1B are diagrams illustrating a complex harness in anembodiment of the present invention, wherein FIG. 1A is a plan view andFIG. 1B is a cross sectional view taken on line 1B-1B;

FIG. 2 is a cross sectional view showing a complex harness in anotherembodiment of the invention;

FIGS. 3A and 3B are cross sectional views showing complex harnesses inanother embodiment of the invention; and

FIGS. 4A and 4B are diagrams illustrating a complex harness in amodification of the invention, wherein FIG. 4A is a plan view and FIG.4B is a cross sectional view taken on line 4B-4B.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The embodiment of the invention will be described below in conjunctionwith the appended drawings.

FIGS. 1A and 1B are diagrams illustrating a complex harness in thepresent embodiment, wherein FIG. 1A is a plan view and FIG. 1B is across sectional view taken on line 1B-1B.

As shown in FIGS. 1A and 1B, a complex harness 1 is provided with acomposite cable 5 composed of an electric brake cable 2 and an ABSsensor cable 3 which are integrated by covering with a common outersheath 4. In addition, the complex harness 1 is configured such that theelectric brake cable 2 and the ABS sensor cable 3 are separated at endportions of the composite cable 5 and a connector 6 is provided at anend portion of least at one of the cables 2 and 3.

The electric brake cable 2 is composed of two power wires 7 and ismainly used as a conducting path for passing an electric current whichis caused to flow therethrough by pressing a given button after stoppinga vehicle to operate a mechanism of preventing rotation of wheels (anelectric parking brake (EPB) mechanism). In addition, it is obvious thatthe electric brake cable 2 can be a cable for a general electric brakeother than for an electric parking brake (EPB) (e.g., a cable includinga control signal wire, etc., in addition to the two power wires 7).

The power wire 7 is formed by covering a center conductor 7 a with aninsulation 7 b. The insulation 7 b is formed of, e.g., XLPE (crosslinkedpolyethylene) or ETFE (tetrafluoroethylene-ethylene copolymer), etc. Inthe electric brake cable 2, the two power wires 7 are generally coveredwith a sheath but, in the invention, the common outer sheath 4 is usedin substitution for the sheath.

Note that, in the present embodiment, it is defined that the compositecable 5 is composed of the electric brake cable 2 and the ABS sensorcable 3 which are integrated by covering with the common outer sheath 4but it can be said, in other words, that the composite cable 5 iscomposed of the electric brake cable 2 and the ABS sensor cable 3 whichis integrated therewith by being embedded into a sheath (the outersheath 4) of the electric brake cable 2.

The two power wires 7 of the electric brake cable 2 extend from both endportions of the composite cable 5. A connector 6 a to be connected to abrake caliper (not shown) is provided at one of the end portions and aconnector 6 b to be connected to a control device (not shown) isprovided at another end portion. A protector 8 formed of a tube or hose,etc., is provided around the two power wires 7 extending from thecomposite cable 5 on each side in order to provide a protection for thepower wires 7 against chipping, etc., caused by a flipped stone.

The ABS sensor cable 3 is formed by covering two signal wires 9 with aninner sheath 10 all together. The signal wire 9 is formed by covering acenter conductor 9 a with an insulation 9 b. The insulation 9 b isformed of, e.g., XLPE, etc. In the present embodiment, the ABS sensorcable 3 is provided so as to be in contact with the power wires 7.

In the present embodiment, the outer sheath 4 is formed of athermoplastic resin, in more detail, a thermoplastic urethane, and theinner sheath 10 is formed of a crosslinked thermoplastic resin, in moredetail, a crosslinked thermoplastic urethane. As shown in FIG. 1B, theouter sheath 4 is provided around the power wires 7 and the ABS sensorcable 3 so as to be interposed therebetween. Although the outer sheath 4is formed by extrusion molding, it is possible to reduce melting of theinner sheath 10 due to heat and fusion-adhesion of the inner sheath 10to the outer sheath 4 resulting therefrom at the time of forming theouter sheath 4 around the inner sheath 10 (at the time of extrusionmolding) by crosslinking the inner sheath 10. As a result, the ABSsensor cable 3 can be easily separated from and taken out of the outersheath 4 at the end portions of the composite cable 5.

Since the thermoplastic urethane used for the outer sheath 4 and theinner sheath 10 is strong against chipping caused by a flipped stone,etc., portions covered with the sheaths 4 and 10 (around the compositecable 5 and around the ABS sensor cable 3 extruding from the compositecable 5) do not need to be covered with a protector. In addition, thethermoplastic urethane is easily bent and is suitable for the complexharness 1 which is used for a wiring under a spring and is repeatedlybent.

Furthermore, in the present embodiment, a thermoplastic urethane havinga silane coupling agent added thereto is crosslinked and is used as theinner sheath 10, and a sensor portion (sensor head) 11 of the ABS sensoris integrated at an end of the ABS sensor cable 3 by a resin mold. Nylonis used as the resin mold. A connector 6 c to be connected to a controldevice (not shown) is provided at another end of the ABS sensor cable 3.

In case that the thermoplastic urethane is crosslinked, it is notpossible to ensure adhesion to the resin mold (nylon, in the presentembodiment). However, by performing the crosslinking treatment afteradding the silane coupling agent to the thermoplastic urethane, silanecoupling agent is activated and this allows adhesion to the resin moldto be improved. As a result, it is possible to ensure adhesion betweenthe inner sheath 10 and the sensor portion 11, thereby reducing waterintrusion into the sensor portion 11. Accordingly, it is possible toreduce troubles of the sensor portion 11 such as breakdown.

Grommets 12 to which a clamp for attaching the composite cable 5 to avehicle body is fixed are attached to the composite cable 5. The grommet12 is formed of, e.g., EPDM (ethylene propylene diene rubber). An innerdiameter of the grommet 12 is expanded by air for attaching the grommet12 to the composite cable 5, and at this time, it is difficult to attachthe grommet 12 if the surface of the outer sheath 4 is not flat.Therefore, in the present embodiment, the outer sheath 4 is formed byperforming extrusion molding twice to obtain the outer sheath 4 having aflat surface, thereby forming the composite cable 5 having asubstantially regular outer shape.

Effects of the present embodiment will be described.

The complex harness 1 in the present embodiment is provided with thecomposite cable 5 composed of the electric brake cable 2 and the ABSsensor cable 3 which are integrated by covering with the common outersheath 4.

Since the electric brake cable 2 and the ABS sensor cable 3 areintegrated, it is possible to effectively use wiring space in a vehicleand to facilitate wiring work. In addition, it is possible to reduce thenumber of wiring parts, which facilitates parts control.

In addition, in the present embodiment, the ABS sensor cable 3 is formedby covering the two signal wires 9 with the inner sheath 10 alltogether, the outer sheath 4 is formed of a thermoplastic resin and theinner sheath 10 is formed of a crosslinked thermoplastic resin.

Therefore, it is possible to reduce melting of the inner sheath 10 dueto heat and fusion-adhesion of the inner sheath 10 to the outer sheath 4resulting therefrom at the time of forming the outer sheath 4 (at thetime of extrusion molding), and accordingly, the ABS sensor cable 3 canbe easily separated from and taken out of the outer sheath 4 at the endportions of the composite cable 5.

Furthermore, in the present embodiment, a thermoplastic urethane havinga silane coupling agent added thereto is used as a material of the innersheath 10, and the sensor portion 11 of the ABS sensor is integrated atan end of the ABS sensor cable 3 by the resin mold.

This allows the inner sheath 10 and the resin mold to be air-tightlyintegrated and it is thereby possible to reduce breakdown etc., of thesensor portion 11 due to water intrusion thereinto. In addition, thenumber of wiring parts is further reduced by integrally providing thesensor portion 11 at an end portion of the ABS sensor cable 3 and it isthus possible to further facilitate wiring work.

Meanwhile, the electric brake cable 2 is used as a conducting path forpassing an electric current which is caused to flow therethrough bypressing a given button after stopping a vehicle to operate a parkingbrake mechanism. Therefore, the ABS sensor cable 3 which is in operationduring running a vehicle does not need measures against noise from theelectric brake cable 2. Therefore, it is possible to integrate theelectric brake cable 2 with the ABS sensor cable 3 without providing anoise suppression shield on at least one of the electric brake cable 2and the ABS sensor cable 3.

Next, another embodiment of the invention will be described.

A complex harness 21 shown in FIG. 2 is based on the complex harness 1shown in FIG. 1 and has a separator 22 provided between the outer sheath4 and the inner sheath 10 to reduce fusion-adhesion thereof.

By providing the separator 22, the ABS sensor cable 3 can be easilyseparated from and taken out of the outer sheath 4 at the end portionsof the composite cable 5 even when both of the outer sheath 4 around theinner sheath 10 are formed of a thermoplastic urethane.

Furthermore, in case that the separator 22 is formed of a metal and isprovided so as to cover the ABS sensor cable 3, the separator 22 servesas a shield and this allows external noise into the signal wire 9 of theABS sensor cable 3 to be reduced. Note that, a material of the separator22 is not limited thereto and it is possible to use, e.g., non-wovenpaper, non-woven fabric (formed of, e.g., PET) or resin tape, etc.

Complex harnesses 31 and 32 respectively shown in FIGS. 3A and 3B arebased on the complex harness 1 shown in FIG. 1 and have a shieldconductor 33 provided so as to cover the two power wires 7 of theelectric brake cable 2. FIG. 3A shows a case where the shield conductor33 is provided so as to cover all of the two power wires 7 and the ABSsensor cable 3 and FIG. 3B shows a ease where the shield conductor 33 isprovided so as to cover only the two power wires 7. Both structures areadoptable. Alternatively, the shield conductor 33 may be provided so asto cover only the ABS sensor cable 3. In case that the shield conductor33 is provided so as to cover all of the power wires 7 and the ABSsensor cable 3 as shown in FIG. 3A, an inclusion 34 is inserted insidethe shield conductor 33, i.e., around the power wires 7 and the ABSsensor cable 3. Meanwhile, by providing the shield conductor 33 so as tocover only the two power wires 7 as shown in FIG. 3B, it is possible toreduce noise into the ABS sensor cable 3 which is in operation duringrunning a vehicle even when the electric brake cable 2 is also used forpassing an electric current during running a vehicle to slow down thevehicle, not only after stopping the vehicle. This allows the electricbrake cable 2 and the ABS sensor cable 3 to be integrated even when theelectric brake cable 2 is also used for passing an electric currentduring running a vehicle to slow down the vehicle, not only afterstopping the vehicle.

Providing the shield conductor 33 allows radiation noise from the powerwires 7 to be suppressed, thereby taking EMI (electromagneticinterference) measures. In addition, when providing the shield conductor33, the shield conductor 33 serves as a separator which separates theABS sensor cable 3 from the outer sheath 4, which reducesfusion-adhesion of the inner sheath 10 to the outer sheath 4 and allowsthe power wires 7 and the ABS sensor cable 3 to be easily separated.

Furthermore, it is possible to provide non-woven paper, non-woven fabric(formed of, e.g., PET) or resin tape, etc., in place of the shieldconductor 33 in FIG. 3A. Providing the non-woven paper or non-wovenfabric in place of the shield conductor 33 allows fusion-adhesion of theinner sheath 10 to the outer sheath 4 to be reduced, and at the sametime, rubbing between the power wires 7 or the ABS sensor cable 3 andthe outer sheath 4 to be reduced and the power wires 7 or the ABS sensorcable 3 to easily move (slip) in the outer sheath 4, which reducesstress due to bending and thus allows flexing endurance to be improved.

It should be noted that the invention is not intended to be limited tothe above-mentioned embodiments, and it is obvious that the variouskinds of modifications can be added without departing from the gist ofthe invention.

For example, the ABS sensor cable 3 is formed by covering the two signalwires 9 with the inner sheath 10 all together in the embodiments, it ispossible to omit the inner sheath 10 as shown in FIGS. 4A and 4B. Inthis case, the signal wires 9 extend from the end portions of thecomposite cable 5 and it is therefore necessary to provide protectors 42formed of a tube or hose, etc., on the exposed portions of the signalwires 9 in order to provide a protection against chipping, etc., causedby a flipped stone. However, in this case, adhesion of the insulation 9b of the signal wire 9 (e.g., XLPE) to the resin mold (e.g., nylon) isnot good enough and it is not possible to integrate the sensor portion11 by the resin mold. Therefore, a connector 43 is provided on thesignal wires 9 at one end and the sensor portion 11 is connected to theconnector.

In addition, the electric brake cable 2 may also be covered with aninner sheath in the same manner as the ABS sensor cable 3 even though itis not mentioned in the embodiments. In this case, in order to preventfusion-adhesion of the inner sheath to the outer sheath 4, a crosslinkedthermoplastic urethane is used for the inner sheath, or, a separator isinterposed between the inner sheath and the outer sheath 4. This allowsthe protector 8 to be omitted and wiring work to be facilitated.

Furthermore, although the outer sheath 4 formed of a thermoplasticurethane has been described in the embodiments, it is not limitedthereto and the outer sheath 4 may be formed of EPDM. Since compressionset (creep) is less likely occur in EPDM, forming the outer sheath 4from the EPDM allows a clamp to be directly fixed to the outer sheath 4without attaching the grommet 12 and it is thus possible to furtherfacilitate wiring work. Note that, since compression set (creep) islikely occur in the thermoplastic resin, it is not possible to directlyfix a clamp thereto and the grommet 12 needs to be provided.

Still further, it is obviously possible to integrate another insulatedwire such as disconnection detection line in addition to the electricbrake cable 2 and the ABS sensor cable 3 even though it is not mentionedin the embodiments.

What is claimed is:
 1. A complex harness, comprising: first electricwires, each of which comprises a first center conductor and a firstinsulation that covers the first center conductor; a cable comprisingsecond electric wires, each of which comprises a second center conductorand a second insulation that covers the second center conductor, and aninner sheath that covers the second electric wires; and an outer sheathcovering the first electric wires and the cable collectively, whereinthe first electric wires are extended from an end of the outer sheath,wherein the cable is extended from the end of the outer sheath in astate where the second electric wires are collectively covered by theinner sheath in such a manner that an extension length of the cable fromthe end of the outer sheath is greater than an extension length of thefirst electric wires from the end of the outer sheath, and wherein aresin mold is integrated at an end of the inner sheath.
 2. The complexharness according to claim 1, wherein each of the second electric wireshas a cross-sectional area smaller than a cross-sectional area of eachof the first electric wires.
 3. The complex harness according to claim1, wherein the outer sheath enters in a space between the first electricwires and the inner sheath.
 4. The complex harness according to claim 3,wherein the inner sheath enters in a space between the second electricwires.
 5. The complex harness according to claim 1, wherein the innersheath enters in a space between the second electric wires.
 6. Thecomplex harness according to claim 1, further comprising a separatorbeing provided between the outer sheath, the first electric wires, andthe cable, the separator comprising a paper, a non-woven fabric, or aresin tape that collectively covers the first electric wires and thecable.
 7. The complex harness according to claim 1, wherein the firstelectric wires contact with each other and the second electric wirescontact with each other.
 8. The complex harness according to claim 7,wherein the first electric wires contact with the inner sheath.
 9. Thecomplex harness according to claim 1, wherein the first electric wirescontact with the inner sheath.
 10. The complex harness according toclaim 1, further comprising a protector comprising a tube or a hoseprovided around an extended part of the first electric wires extendingfrom the end of the outer sheath, wherein the protector is absent aroundan extended part of the cable extending from the end of the outersheath.